Refrigerated, Chemically Leavened Doughs in Package, with Carbon Dioxide Atmosphere

ABSTRACT

Described are methods and compositions relating to dough compositions leavened by chemical leavening systems that include acidic chemical leavening agent and encapsulated basic chemical leavening agent, wherein the dough composition can be refrigerated in a low pressure package that contains a carbon dioxide atmosphere.

REFERENCE TO RELATED APPLICATION

This application a continuation of application Ser. No. 11/577,885,filed Apr. 25, 2007, which is a National Stage of Application No.PCT/US2005/039188, filed Oct. 28, 2005, which claims the benefit ofpriority under 35 U.S.C. §119(e)(1) of a provisional patent application,Ser. No. 60/623,428, filed Oct. 29, 2004, which are incorporated hereinby reference in their entirety.

FIELD OF THE INVENTION

The invention relates to refrigerator-stable, chemically-leavened, doughcompositions, dough products, and methods for preparing the same.

BACKGROUND

Today's commercial and consumer dough products are designed toaccommodate consumer preferences in terms of convenience of use, storagestability, and organoleptic properties such as taste, texture, aroma,and color. One popular type of consumer dough product is the class ofrefrigerator-stable, chemically-leavened, dough products, a singleexample being refrigerated soda biscuits. These dough products areleavened substantially by the action of chemical leavening agents, asopposed to yeast, and they can be packaged to be stable over certainperiods of time at refrigerated conditions.

Consumers appreciate the convenience of refrigerator-stable doughcompositions, e.g., because of the convenience of allowing arefrigerated dough to be prepared, stored, and used at a convenienttime. Refrigerated doughs should desirably produce a cooked doughproduct having properties comparable to cooked doughs prepared withoutan extended period of refrigerated storage, such as desired taste,aroma, texture, leavening properties, and color.

A key consideration in the feasibility of a commercial dough product iswhether a storage-stable dough product can be prepared and packaged inan economical manner. Whether this is possible can depend on factorssuch as a packaging configuration and packaging materials. Packaging ofa refrigerator-stable dough product can contribute to retainingfreshness over an extended period of refrigerated storage. Many types ofpackaging materials and package forms are used commercially, includingpressurized cans and non-pressurized pouches or chubs.

SUMMARY

The invention relates to raw, chemically-leavened (i.e.,chemically-leavenable) dough compositions, packaged dough products, andrelated methods. The doughs include a chemical leavening system thatincludes a basic chemical leavening agent and acidic chemical leaveningagent, and can be packaged in a low pressure package having a carbondioxide atmosphere, for refrigerated storage.

Past attempts to improve stability of dough compositions duringrefrigerated storage have involved a reduction or elimination of packageheadspace, with the use of vacuum. According to these methods, it can bepreferred to have the dough composition frozen when vacuum is applied,to prevent damage to the dough. The step of freezing the dough, however,adds cost and complication to the process.

According to the invention, refrigerator-stable dough compositions canbe packaged in low pressure packaging, without having to be frozen whilesubjected to vacuum, with the resultant packaged dough still exhibitingdesired refrigerated storage stability. This can be accomplished, basedon the invention, by using a headspace that includes an added carbondioxide atmosphere (without freezing the dough, or eliminatingheadspace), and with the use of an amount of headspace and carbondioxide atmosphere that does not exceed 0.5 cubic centimeters headspaceper gram dough, e.g., from 0.1 to 0.5 cubic centimeters headspace pergram of dough.

A low pressure package can mean a package that is substantially airtight, with an internal pressure that, typically, is about 1 atmosphereor 15 psia (pounds per square inch, absolute), or slightly greater.Examples of low pressure packages include chubs and pouches that do notexhibit a pressurized interior. Low pressure packages specificallyexclude pressurized cans and canisters, e.g., of cardboard, that containdough products at an internal pressure of at least 15 psig.

According to the invention, a raw, chemically leavenable doughcomposition is packaged in a carbon dioxide atmosphere, with the amountof carbon dioxide being based on the amount of dough in a package.Headspace refers to the amount of volume of the packaged dough productnot taken up by dough composition; i.e., the internal volume not takenup by the dough product. (Headspace does not include potential space notused but available in the form of wrinkled or folded packagingmaterial.) The headspace of a packaged dough composition, and the volumeof carbon dioxide atmosphere, can be up to 0.5 cubic centimetersheadspace and carbon dioxide atmosphere per gram of dough contained inthe package. A carbon dioxide atmosphere refers to a substantiallyconcentrated carbon dioxide atmosphere, including a gaseous atmospherethat contains at least 90 percent carbon dioxide, e.g., at least 95 or99 percent carbon dioxide.

Specific embodiments of the invention include, but are not limited by,un-proofed, non-developed doughs in a low pressure package, e.g.,biscuit doughs, that contains chemical leavening agent including anencapsulated basic chemical leavening agent, a relatively low solubilityacidic chemical leavening agent, and glucose oxidase.

Exemplary dough compositions packaged according to the invention canevolve less than 80 cubic centimeters (cc) of carbon dioxide per 125grams of dough over an 8, 10, or 12 week period of time while stored at45 degrees Fahrenheit, e.g., from 60 to 80 cc of carbon dioxide per 125grams over 8, 10, or 12 weeks at 45° F. Such a dough can undergo adesired amount of leavening during such period of refrigerated storage,to produce a dough composition having a raw specific volume in the rangefrom 0.9 to 1.6 cc/gram.

Upon baking, exemplary non-developed dough compositions of the inventioncan exhibit leavening and baked specific volume properties that aretypical of normal non-developed doughs, e.g., can be baked to a specificvolume of at least 2 or 2.5 cc/g, e.g., from 2.5 to 3.4 cc/g.

As used in the present description, the terms “proof” and “proofing”relate to an occurrence prior to baking of a dough composition thatentails at least partial expansion (i.e., at least partial proofing) ofa dough composition resulting from the reaction of chemical leaveningagents or from the metabolic action of yeast to evolve CO2 gas thatexpand bubbles within the dough composition and thereby expand the doughcomposition to a desired volume and optionally to a desired shape.

In one aspect, the invention relates to a refrigerated dough productthat includes a raw, chemically-leavened dough composition in a lowpressure package. The dough composition includes encapsulated basicchemical leavening agent, acidic chemical leavening agent, and glucoseoxidase. The packaging containing headspace containing a carbon dioxideatmosphere. And, the ratio of carbon dioxide volume to dough mass, uponpackaging, is less than or equal to 0.5 cubic centimeters per gram.

In another aspect the invention relates to a method of providing a doughproduct. The method includes providing a non-frozen, raw,chemically-leavened dough composition; placing the non-frozen doughcomposition in a low pressure package, the package having a ratio ofheadspace volume to dough mass of no greater than 0.5 cubic centimetersheadspace per gram; flushing the headspace with carbon dioxide; sealingthe package to contain the dough composition in a carbon dioxideheadspace; storing the dough composition at a refrigerated storagetemperature; and cooking (e.g., baking) the dough composition.

DETAILED DESCRIPTION

Dough compositions according to the invention includechemically-leavened dough compositions (i.e., “chemically-leavenable”dough compositions), which are dough compositions that leaven to asubstantial extent by the action of chemical ingredients that react toproduce a leavening gas. Typically, the ingredients include a basicchemical leavening agent and an acidic chemical leavening agent, the twoof which react to produce carbon dioxide that, when retained by thedough matrix, causes the dough to expand. Chemically-leavened doughs canbe contrasted to dough formulations that are substantially leavened dueto the action of yeast as a leavening agent, i.e., by metabolic actionof yeast on a substrate to produce carbon dioxide. While doughs of theinvention can include yeast, e.g., as a flavoring agent, certain doughcompositions of the invention do not include yeast as a leavening agent.

The degree of development of a dough (as in a “developed” versus a“non-developed” dough) generally refers to the strength of a dough'smatrix, as the strength relates to the degree of development of gluten(protein) in a dough matrix. During processing of a dough composition,gluten can be caused or allowed to interact or react and “develop” adough composition in a way that increases the stiffness, strength, andelasticity of the dough. Doughs commonly referred to as “developed”doughs are generally understood to include doughs that have a relativelyhighly-developed gluten matrix structure; a stiff, elastic rheology; and(due to the stiff, elastic matrix) are well able to form bubbles orcells that can stretch without breaking to hold a leavening gas whilethe dough expands, leavens, or rises, prior to or during cooking (e.g.,baking). Features that are sometimes associated with a developed dough,in addition to a stiff, elastic rheology, include a sufficient (e.g.,relatively high) protein content to allow for a highly-developedstructure; optionally, processing steps that include time to allow thedough ingredients (e.g., gluten) to interact and “develop” to strengthenthe dough; and on average a baked specific volume that is relativelyhigher than non-developed doughs. Oftentimes, developed doughs areyeast-leavened, but may be chemically leavened. Examples of specifictypes of doughs that can be considered to be developed doughs includedoughs for pizza crust, breads (loaves, dinner rolls, baguettes, breadsticks), raised donuts, cinnamon rolls, croissants, Danishes, pretzels,etc.

As compared to “developed” doughs, doughs commonly referred to asnon-developed (or “un-developed” or “under-developed”) have a relativelyless developed (“undeveloped”) dough matrix that gives the dough arelatively less or reduced elastic rheology, reduced strength, andreduced gas-holding capacity. Being less elastic than a developed doughand exhibiting a reduced gas-holding capacity, non-developed doughs, onaverage, exhibit relatively lower raw and baked specific volumes.

Chemically-leavened, non-developed, dough compositions can be preparedfrom ingredients generally known in the dough and bread-making arts,typically including flour, a liquid component such as oil or water, achemical leavening system, fat (solid or liquid), and optionallyadditional ingredients such as salt, sweeteners, dairy products, eggproducts, processing aids, emulsifiers, particulates, doughconditioners, yeast as a flavorant, other flavorings, and the like.Exemplary compositions do not include yeast as a leavening agent, andsuch doughs are leavened entirely based on the action of the chemicalleavening agents.

Acidic chemical leavening agents are generally known in the dough andbread-making arts, with examples including sodium aluminum phosphate(SALP), sodium acid pyrophosphate (SAPP), monosodium phosphate,monocalcium phosphate monohydrate (MCP), anhydrous monocalcium phosphate(AMCP), dicalcium phosphate dihydrate (DCPD), glucono-delta-lactone(GDL), as well as a variety of others. Commercially available acidicchemical leavening agents include those sold under the trade names:Levn-Lite® (SALP), Pan-O-Lite® (SALP+MCP), STABIL-9® (SALP+AMCP),PY-RAN® (AMCP), and HT® MCP (MCP). Optionally, an acidic chemicalleavening agent for use according to the invention (either soluble orinsoluble), can be encapsulated. According to certain specificembodiments of the invention, a chemically-leavenable dough includesnon-encapsulated, acidic chemical leavening agent that is relativelyinsoluble in a liquid (e.g., aqueous) component of the doughcomposition, at a temperature used during processing (e.g., from 40 toabout 72 degrees Fahrenheit) or refrigerated storage (e.g. from about 32to about 55 degrees Fahrenheit). Particularly useful acidic chemicalleavening agents that are considered to exhibit a relatively lowsolubility at processing temperature, include sodium aluminum phosphate(SALP), sodium acid pyrophosphate (SAPP) having a relatively lowsolubility, and other acidic chemical leavening agents that exhibitsimilar solubility behavior.

Acidic chemical leavening agent can be present in a dough composition inan amount that provides one or more useful properties as describedherein, including refrigerated stability, desired refrigerated rawspecific volume, and desired leavening properties during and followingrefrigerated storage. A typical amount of acidic agent such as SALP maybe in the range from about 0.25 to about 2 parts by weight per 100 partsdough composition, with ranges from about 0.25 to about 1.5 parts byweight per 100 parts dough composition sometimes being particularlyuseful. These amounts, and amounts of acidic agent identified throughoutthe present application and claims, do not including encapsulating agentunless otherwise noted.

The dough composition also includes basic chemical leavening agent.Useful basic chemical leavening agents are generally known in the doughand baking arts, and include soda, i.e., sodium bicarbonate (NaHCO₃),potassium bicarbonate (KHCO₃), ammonium bicarbonate (NH₄HCO₃), etc.These and similar types of basic chemical leavening agents are generallyfreely soluble in an aqueous component of a dough composition atprocessing and refrigerated storage temperatures.

The amount of basic chemical leavening agent used in a dough compositionmay be sufficient to react with the included acidic chemical leaveningagent to release a desired amount of gas for leavening, thereby causinga desired degree of expansion of the dough product. The typical amountof a basic chemical leavening agent such as sodium bicarbonate may be inthe range from about 0.2 or 0.25 to about 1.5 weight percent based onthe total weight of a dough composition, including the range from about0.75 to about 1.25 weight percent based on total weight of a doughcomposition. (As used throughout this description and claims, unlessotherwise noted, amounts of basic chemical leavening agents andencapsulated basic chemical leavening agents are given in terms of theamount of active basic agent, not including the weight of anyencapsulant or barrier material.)

According to specific embodiments of the invention, a basic agent can beencapsulated, and can be used in combination with a relatively lowsolubility acidic agent. Encapsulated basic chemical leavening agentsare generally known, and can be prepared by methods known in the bakingand encapsulation arts. An example of a method for producing enrobedparticles is the use of a fluidized bed.

Encapsulated basic chemical leavening agents are typically particlesthat include solid basic chemical leavening agent particulates coveredin part, e.g., substantially completely, by a barrier material orencapsulant. Encapsulated particles are known in the baking arts, andinclude encapsulated particles sometimes referred to as “enrobed”particles, as well as those sometimes referred to as “agglomerated”particles. The barrier material or encapsulant forms a coating or shellaround a single or multiple particulates of solid basic chemicalleavening agent, separating the chemical leavening agent from a bulkdough composition. “Enrobed” particles generally include a singleparticulate of chemical leavening agent covered or coated by barriermaterial, and “agglomerate” particles generally include 2, 3, or moreparticulates of chemical leavening agent contained in a mass of barriermaterial.

Encapsulating the basic chemical leavening agent provides separationbetween the basic chemical leavening agent and the bulk of the doughcomposition to inhibit, prevent, or slow the progress of reaction of thebasic and acidic leavening agents. On the other hand, due to cracks,incomplete coverage, or damage to encapsulated particles, some amount ofbasic agent can be exposed, allowing it to dissolve into a doughcomposition, contact dissolved acid, and react to produce carbondioxide. Due to such imperfect encapsulation, dissolved acidic agent canreact with an amount of exposed basic agent, during processing orrefrigerated storage, to produce carbon dioxide gas that can expand(e.g., proof or partially proof) the dough.

A non-developed, chemically-leavened dough composition according to theinvention can include other dough ingredients as known in the dough andbaking arts, or as developed in the future to be useful withchemically-leavened, non-developed dough compositions.

Certain embodiments of doughs according to the invention can alsoinclude an oxidoreductase enzyme to prevent enzymatic doughdiscoloration by reacting with oxygen, e.g., as explained in Applicantsco-pending U.S. patent application Ser. No. 10/446,483, filed May 28,2003, entitled METHOD OF PREVENTING DISCOLORATION OF DOUGH, DOUGHCOMPOSITIONS, AND DOUGH PRODUCTS, the entire contents of which areincorporated herein by reference. Oxidoreductase enzymes are generallyknown, and are described, for example, at Whitaker, John R., Principlesof Enzymology for the Food Sciences, 2^(nd) Ed., Chapters 21-27, p. 517et. seq. Examples of oxidoreductase enzymes include glucose oxidase andlactate dehydrogenase, among many others. The dough composition includesa substrate such as glucose that can react with oxygen in the presenceof an oxidoreductase enzyme, to consume oxygen and prevent the oxygenfrom being available to react to discolor the dough composition. Theparticular substrate and amount used can depend on various factorsrelating to the dough composition and packaged dough product, inparticular, on the oxidoreductase enzyme that is selected.

Glucose (or any other substrate that reacts with oxygen in the presenceof an oxidoreductase enzyme) can be present in a dough composition as aseparately added ingredient, e.g., as a sweetener or other additive, ormay be contained in one of the other ingredients included in the doughcomposition. The amount of the substrate in a dough composition of theinvention can be any amount that in combination with an oxidoreductaseenzyme (e.g., glucose oxidase) results in the depletion of oxygen withinthe dough composition or packaged dough product to the extent that theextent of dough discoloration (e.g., graying) is reduced or eliminatedupon subsequent refrigerated or frozen storage prior to being baked.Exemplary amounts of glucose may be in the range from about 1 to about40 percent (Baker's percent), e.g., from about 5 to about 30 Baker'spercent.

An oxidoreductase enzyme such as glucose oxidase can be included in thedough composition itself, in only a portion of the dough compositionsuch as at a surface, or elsewhere in a packaged dough composition at alocation effective to inhibit or prevent discoloration. Theoxidoreductase enzyme can be any enzyme that effectively causes anon-discoloring reaction between oxygen and a substrate to consumeoxygen within the dough composition or packaged dough product andprevent the oxygen from otherwise reacting to cause discoloration of thedough composition. A preferred example of a useful oxidoreductase enzymeis glucose oxidase.

The amount of oxidoreductase enzyme that can be included in the doughproduct or the dough composition can be any amount that will beeffective to react with and consume oxygen and prevent reaction ofoxygen to produce discoloration of the dough composition. The particularamount used in a dough composition or dough product can depend onvarious factors, such as the type of dough composition and ingredientsused in the dough composition, the type of dough product packaging(including the amount of headspace and the amount of oxygen in theheadspace, if any), the amount of surface area of the dough product, theprocessing and packaging history of the dough product, the intendedstorage conditions of the dough composition or dough product, and howeach of these and other factors affect the amount of oxygen present in adough composition or a dough product.

Exemplary amounts of glucose oxidase as an oxidoreductase enzyme, foruse in chemically leavenable dough composition packaged in a flexiblepackage with a carbon dioxide atmosphere as described herein, can be inthe range from about 0.025 glucose oxidase activity units per gram doughto about 0.25 glucose oxidase activity units per gram dough, e.g., fromabout 0.025 to about 0.075 glucose oxidase activity units per gramdough. Amounts of glucose oxidase ingredient, e.g., GLUZYME 2.500 BGmanufactured by Novozymes, which compare to the above ranges, can beamounts in the range from about 0.001 to 0.01 weight percent GLUZYME2500 BG based on the total weight of the dough composition.

A flour component can be any suitable flour or combination of flours,including glutenous and nonglutenous flours, and combinations thereof.The flour or flours can be whole grain flour, flour with the bran and/orgerm removed, or combinations thereof. Typically, a dough compositioncan include between about 30 and about 55 weight percent flour, e.g.,from about 35 to about 50 weight percent flour, based on the totalweight of a dough composition.

Examples of liquid components include water, milk, eggs, and oil, or anycombination of these, as will be understood to be useful inchemically-leavened, non-developed dough compositions. For example, aliquid component may be water (added as an ingredient and as part ofother ingredients), e.g., in an amount in the range from about 15 to 35weight percent, although amounts outside of this range may also beuseful. Water may be added during processing in the form of ice, tocontrol the dough temperature in-process; the amount of any such waterused is included in the amount of liquid components. The amount ofliquid components included in any particular dough composition candepend on a variety of factors including the desired moisture contentand rheological properties of the dough composition. Typically, liquidscan be present in a dough composition in an amount between about 15percent by weight and about 35 percent by weight, e.g., water in anamount in the range from 25 to 35 weight percent based on total weightof a dough composition.

The dough composition can optionally include fat ingredients such asoils and shortenings. Examples of suitable oils include soybean oil,corn oil, canola oil, sunflower oil, and other vegetable oils. Examplesof suitable shortenings include animal fats and hydrogenated vegetableoils. Fat may be used in an amount less than about 20 percent by weight,often in a range from 5 or 10 weight percent to 20 weight percent fat,based on total weight of a dough composition.

The dough composition can optionally include one or more sweeteners,either natural or artificial, liquid or dry. Examples of suitable drysweeteners include lactose, sucrose, fructose, dextrose, maltose,corresponding sugar alcohols, and mixtures thereof.

One specific example of a non-developed dough that can be prepared andpackaged according to the invention, is a chemically leavened biscuitdough. Such a dough may include, for example, ingredients within thefollowing ranges: from 30 to 50 weight percent flour, from 5 to 20weight percent fat, from 0.025 to 0.25 weight percent glucose oxidase,from 0.6 to 1.2 weight percent non-encapsulated acidic chemicalleavening agent with a neutralization value of 100% (e.g., SALP)(neutralization value is the weight of soda neutralized by 100 partsleavening acid), and from 0.6 to 1.2 weight percent encapsulated basicchemical leavening agent at 75% activity (not including the weight ofany encapsulant), based on the total weight of the dough composition.

Dough compositions described herein can be prepared according to methodsand steps that are known in the dough and dough product arts. These caninclude steps of mixing or blending ingredients, folding, lapping,forming, etc., which are steps well known in the dough and baking arts.According to particular methods, wherein a dough composition includes anencapsulated basic leavening agent, a dough can be prepared by methodsthat prevent or avoid substantial or excessive damage to encapsulatedbasic chemical leavening agent particles. Methods of incorporatingencapsulated basic chemical leavening agent into a dough composition caninclude using reduced amounts of shear, such as by using high speed orhigh shear mixing for a reduced amount of time, or by using a low shearmethod. Such methods are described in Assignee's co-pending U.S. patentapplication Ser. No. 10/224,886, entitled Methods of IncorporatingEncapsulated Chemical Leavening Agent into Dough Ingredients, andCompositions So Prepared, filed Aug. 21, 2002, the entirety of which isincorporated herein by reference.

A dough composition, once prepared from ingredients as described, can befurther processed as desired to prepare a final dough composition.Depending on the type of final dough composition, certain steps ofsheeting, folding, lapping with and without shortening or fat, enrobing,cutting, filling, and shaping, can be used to form a particular shapeand form of dough product.

A dough composition as described herein can be prepared, stored, andsold or used, as is typical or otherwise useful for refrigerated,developed, chemically-leavened dough compositions, and consistent withthe present description. According to the invention, an unproofed, raw,chemically-leavenable dough composition can be packaged in alow-pressure package having a ratio of headspace to dough volume of nogreater than 0.5 cubic centimeters headspace per gram dough. Exemplaryratios of headspace to dough volume can be in the range from 0.1 to 0.5cubic centimeters headspace per gram of dough (e.g., at 45 degreesFahrenheit), e.g., from 0.4 to 0.5 cubic centimeters headspace per gram.The headspace is an atmosphere of concentrated carbon dioxide, e.g., anatmosphere that contains at least 90 percent, 95 percent, or at least 99percent carbon dioxide. This refers to the carbon dioxide as containedby the package upon closing or sealing the package, and at a processingtemperature. A processing temperature may be from above freezing toabout room temperature, or slightly above. Typical processingtemperatures may be in the range from 35 to 50 degrees Fahrenheit, e.g.,45 degrees Fahrenheit.

Examples of low pressure or non-pressurized packaging configurationsinclude plastic tubes, chubs, and pouches. A low pressure package caninclude packaging may optionally include a rigid material such as arigid plastic tray in combination with a flexible film portion thatcloses or encloses the tray, optionally but not necessarily including apressure relief valve. A low pressure, or non-pressurized container,means that the packaging is not designed to produce or maintain apressurized interior space, e.g., an interior pressure greater thanapproximately 1.5 atm (absolute). The packaging material does notrequire a pressure relief valve.

Exemplary packaging materials that may be useful for non-pressurizedpouch, tube, or chub packaging, can include flexible plastic materialsthat act as an adequate barrier to gases such as oxygen and carbondioxide, to promote storage and freshness. The material of the flexiblepackage can be any of a variety of flexible materials, generally films,useful in packaging food or dough products. Flexible refers to theability of a packaging material to bend and change shape as describedherein, and does not require the material to stretch.

Exemplary flexible packaging materials include flexible films orfilm-like materials such as polymeric films or flexible paper or foilmaterials. The flexible packaging does not need to include stiffcardboard, cardboard cans, or other non-flexible materials. Exemplaryflexible film materials can be continuous single or multi-layer filmsthat are flexible and impermeable to gases such as oxygen, carbondioxide, water vapor, or combinations of these. A substantially airtight flexible packaging can be prepared from materials such as paper orpolymeric materials or foils, with especially preferred materialsincluding multi-layer polymeric (e.g., plastic) films. A polymeric filmmay be prepared from generally well known packaging material polymerssuch as different polyesters (e.g., PET), nylons, polyolefins (e.g.,polyethylene), vinyls, polyalcohols, etc.

According to certain embodiments of the invention, the dough compositioncan be packaged in an unproofed condition, and can experience a certainamount of leavening (e.g., partially proofing) while packaged, e.g.,during refrigerated storage. As a specific example, an unproofed doughcomposition, e.g., having a raw specific volume in the range from 0.9 to1.2 cc/g can be placed in a flexible package containing headspace andadded carbon dioxide atmosphere as described, i.e., wherein the amountof headspace and added carbon dioxide is less than 0.5 cubic centimeterscarbon dioxide per gram of dough in a package. During refrigeratedstorage, the unproofed dough composition can experience an amount ofleavening (e.g., proofing) while inside the package, to result in a rawspecific volume of a partially-proofed dough composition, e.g., from 1.2to 1.7 cc/g. This leavening occurs due to reaction between the solubleacidic agent with the basic chemical leavening agent—dissolved acid canreact with an amount of basic agent that is exposed to the acid due toimperfect encapsulation. An additional amount of expansion of the doughalso occurs as the result of the added carbon dioxide in the headspace,which diffuses into the dough from the headspace and is subsequentlyreleased into the dough gas cells.

According to methods of the invention, the dough composition can bepackaged in a low pressure package to include an amount of headspace, asdescribed herein, and the headspace can be flushed with concentratedcarbon dioxide, e.g., at least 90 percent carbon dioxide.Advantageously, the dough can be placed in the package, and the packagecan be flushed with carbon dioxide, without having the dough at a frozentemperature (as is sometimes done when vacuum is applied to removeheadspace). For example, the dough may be at any processing temperature,such as from about freezing, e.g., 32 degrees Fahrenheit, to roomtemperature or above. A temperature that is in the range of a usefulprocessing or refrigeration temperature may be particularly useful,e.g., a temperature in the range from 60 to 70 degrees Fahrenheit.

Optionally, an amount of vacuum may be used to remove a portion ofheadspace from the package. If so, a cooler dough may be more tolerantto exposure to vacuum. Vacuum, for example, may be used to reduceheadspace volume and the amount of carbon dioxide to which the packageddough is exposed, which means less carbon dioxide will be absorbed bythe dough and the dough will experience a reduced amount of expansionover shelf life time, which may provide desired stability andperformance. As a specific example, a dough composition cooled toapproximately 40° F. can be exposed to a vacuum of up to approximately ⅔atmosphere (335 mb).

A packaged dough product containing carbon dioxide headspace at lessthan 0.5 cubic centimeters for each gram of dough (upon packaging) canbe stored at refrigerated temperatures, and is stable for multipleweeks. In general, an amount of carbon dioxide headspace that exceeds0.5 cc per gram of dough (at packaging) can produce an amount ofexpansion during refrigerated storage that is undesirably high. Whenexpansion is too great, the dough can become malformed and may not baketo a desired shape. Limiting the amount of carbon dioxide in the packageheadspace has been found to control (e.g., minimize) the extent ofundesired expansion and deformation over refrigerated storage.

Somewhat more specifically, exemplary dough compositions when packagedaccording to the invention, with added CO₂ in the package headspace notto exceed 0.5 cc/gm dough, can evolve less than 40 cubic centimeters(cc) of carbon dioxide per 125 grams of dough over an 8, 10, or 12 weekperiod of time while stored at 45 degrees Fahrenheit, e.g., from 30 to40 cc of carbon dioxide per 125 grams over 8, 10, or 12 weeks at 45° F.Such a dough can undergo a desired amount of leavening during suchperiod of refrigerated storage, to produce a dough composition having araw specific volume in the range from 0.9 to 1.6 cc/gram.

Upon baking, exemplary non-developed dough compositions of the inventioncan exhibit leavening and baked specific volume properties that aretypical of normal non-developed doughs, e.g., can be baked to a specificvolume of at least 2 or 2.5 cc/g, e.g., from 2.5 to 3.4 cc/g.

Exemplary embodiments of the invention are described herein. Variationson the exemplary embodiments will become apparent to those of skill inthe relevant arts upon reading this description. The inventors expectthose of skill to use such variations as appropriate, and intend for theinvention to be practiced otherwise than specifically described herein.Accordingly, the invention includes all modifications and equivalents ofthe subject matter recited in the claims as permitted by applicable law.Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated.

1. A packaged refrigerated dough product comprising: an unproofed, raw,chemically-leavenable non-developed dough composition, the doughcomposition including an encapsulated basic chemical leavening agent, anacidic chemical leavening agent, and glucose oxidase; and a packagecontaining the dough composition and a carbon-dioxide-flushed headspacecontaining at least 90 percent carbon dioxide with a ratio of headspacevolume to dough volume is less than or equal to 0.5 cubic centimetersper gram, wherein the packaged refrigerated dough product is capable ofbeing stored for 40 days at 45 degrees Fahrenheit, during which storagethe dough composition has a raw specific volume not greater than 1.7cubic centimeters per gram.
 2. The product of claim 1 wherein the doughproduct is at a temperature in the range from 35 to 50 degreesFahrenheit.
 3. The product of claim 1 wherein the dough compositioncomprises from 0.025 to 0.25 glucose oxidase units per gm dough.
 4. Theproduct of claim 1 comprising acidic chemical leavening agent selectedfrom the group consisting of non-encapsulated sodium aluminum phosphate,non-encapsulated sodium acid pyrophosphate, and combinations thereof. 5.The product of claim 1 wherein the dough is a non-developed doughcomprising: from 35 to 50 weight percent flour, from 5 to 20 weightpercent fat, from 0.025 to 0.25 weight percent glucose oxidase, from 0.6to 1.2 weight percent non-encapsulated acidic chemical leavening agent,and from 0.6 to 1.2 weight percent encapsulated basic chemical leaveningagent, based on the total weight of the dough composition.
 6. Theproduct of claim 1 wherein the carbon dioxide atmosphere comprises atleast 95 percent carbon dioxide.
 7. The product of claim 1 wherein thepackaged refrigerated dough product is capable of being stored for 40days at 45 degrees Fahrenheit, during which storage an interior pressureof the package does not exceed 1.7 atmosphere (absolute).
 8. The productof claim 7 wherein the package is a thermally-formed pouch.
 9. Theproduct of claim 7 wherein the package is a flexible chub or pouchpackage that does not include a pressure release valve.
 10. The productof claim 1 wherein the concentration of carbon dioxide in the headspaceis sufficient to allow carbon dioxide of the headspace to diffuse intothe dough from the headspace during the refrigerated storage.
 11. Theproduct of claim I wherein the packaged refrigerated dough product iscapable of being stored for 40 days at 45 degrees Fahrenheit, duringwhich storage the dough composition has a raw specific volume in a rangefrom 1.2 to 1.5 cubic centimeters per gram.
 12. The product of claim 1wherein the ratio of headspace volume to dough volume is less than orequal to 0.1 cubic centimeters per gram.
 13. A method of providing adough product, the method comprising providing an unproofed non-frozen,raw, chemically-leavenable non-developed dough composition including anencapsulated basic chemical leavening agent, a low solubility acidicchemical leavening agent, and glucose oxidase, placing the non-frozendough composition in a package, the package having a ratio of headspacevolume to dough mass of no greater than 0.5 cubic centimeters headspaceper gram, flushing the headspace with carbon dioxide, sealing thepackage to contain the dough composition in the headspace, including atleast 90 percent carbon dioxide.
 14. The method of claim 13 wherein thedough composition comprises an acidic chemical leavening agent selectedfrom the group consisting of non-encapsulated sodium aluminum phosphate,non-encapsulated sodium acid pyrophosphate, and combinations thereof.15. The method of claim 13 further comprising sealing the package tocontain from 0.1 to 0.5 cubic centimeters carbon dioxide per gram ofdough at about 1 atmosphere and a temperature of 35 to 50 degreesFahrenheit.
 16. The method of claim 13 further comprising sealing thepackage to contain from 0.4 to 0.5 cubic centimeters carbon dioxide pergram of dough at about 1 atmosphere and a temperature of 35 to 50degrees Fahrenheit.
 17. The method of claim 13 wherein after 40 days ofrefrigerated storage at 45 degrees Fahrenheit, the dough composition hasa raw specific volume in the range of from 0.95 to 1.5 cubic centimetersper gram.
 18. The method of claim 13 wherein after 40 days ofrefrigerated storage: the dough composition has a raw specific volume inthe range from 0.95 to 1.5 cubic centimeters per gram, and the doughcomposition can be baked to a baked specific volume in the range from2.5 to 3.4 cubic centimeters per gram.
 19. The method of claim 13further comprising subjecting the package, containing the non-frozen rawdough composition, to vacuum.
 20. The method of claim 13 wherein thedough is a non-developed dough comprising: from 35 to 50 weight percentflour, from 5 to 20 weight percent fat, from 0.025 to 0.25 weightpercent glucose oxidase, from 0.6 to 1.2 weight percent non-encapsulatedacidic chemical leavening agent, and from 0.6 to 1.2 weight percentencapsulated basic chemical leavening agent, based on the total weightof the dough composition.
 21. The method of claim 13 wherein theconcentration of carbon dioxide in the headspace is sufficient to allowcarbon dioxide of the headspace to diffuse into the dough from theheadspace during the refrigerated storage.
 22. The method of claim 13wherein the refrigerated dough product is capable of being packaged for40 days of refrigerated storage at 45 degrees Fahrenheit, during whichthe dough composition has a raw specific volume in the range of from0.95 to 1.7 cubic centimeters per gram.
 23. The method of claim 13wherein the ratio of headspace volume to dough volume is less than orequal to 0.1 cubic centimeters per gram.